We seem to be pushing the K10s and Yamaha sub a little too hard to get the volume we need.
We definitely plan to add a 2nd sub. My main question is about the mains. We'd like to keep what we have and add to it, rather than replace pieces. Simply add 2 more K10's? Or should we replace them in favor of larger drivers?

The K10's sound fantastic and yes, 2 (and even the single sub) are fine for smaller gigs. We just need more volume.
I hadn't thought of using them as monitors. That would save some space - those Peaveys are huge!

Not sure about adding another set of K10's. You might want to head over to the QSC forum and ask that. K12's will punch a little harder. There is a little more acoustic output AND the dispersion is 75 degrees rather than 90 for the K10's. So that acoustic energy is focused in a smaller area.

I own K10's and have mixed on K12's. They both sound great. I picked the 10's for the wider dispersion which works for the gig's I do, venues I play. I'd love to add a K8 as in-fill...

We seem to be pushing the K10s and Yamaha sub a little too hard to get the volume we need.
We definitely plan to add a 2nd sub. My main question is about the mains. We'd like to keep what we have and add to it, rather than replace pieces. Simply add 2 more K10's? Or should we replace them in favor of larger drivers?

Thanks TB!

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Based on my reading, you have a 1000 watts from each main and 1000 watts from the sub, 3k watts total. Seems like you just need to move more air.

Another thing to consider is the setup: Are you running the mains from the sub thoughputs? Are the mains set in the External sub mode? Where is the sub placed during a gig? Is the HPF set on the sub? Maybe you're getting more distortion due to the setup?

If you're going to stick with QSC, I suggest two K12's per side vertically stacked with the horns next to each other and another sub placed at right angle to your current one in front of the stage. +1 to using the K10s as monitors. It is highly NOT recommended to put subs on each side of the stage due to frequency cancellations. Check out: Sub stage placement w plots/graphs

+1 to checking out Bill Fitzmaurice cabs. You can have them built for you by an authorized builder. They're much more efficient, take way less power and probably cost less the more QSC stuff. Just add an amp to the Mackie for mains power and then pickup another QSC sub (run signal from the Mackie sub out). Use the 10's for monitors in full range mode.

The sub is on whatever side of the stage I'm on, facing out. I put the mixer next to it and I'm the guy who gets to run the sound from stage. One K10 is pole mounted on the sub, one is on a stand by itself on the other side of the stage. I don't claim to know everything about this stuff, but my bandmates are even less adept, so there ya go.

First, I really don't believe any of those amps are actually doing 1000w. And I don't buy into wattage anyway. In fact, one of the guitarists bought all this stuff (God love him). It's not what I would have picked out. I will add that I'm completely happy with how the system sounds. Setup / teardown is a breeze too. We just need more volume out of it. I'm seeing the clip lights a lot and noticing we're not really filling some of the larger rooms we're starting to play.

Anyway, yes, running L+R from mixer into sub, using the sub's throughput to connect mains. Low pass is set on the sub, the QSC's are set to "EXT SUB" (high pass). The crossover freq on both is 100hz.

What I'm thinking of doing is adding another Yamaha DSR118w and two powered 15" mains, and relegating the K10s to monitor detail. I know the masses seem to like 12's better when using subs, and that's not ruled out, but leaning toward 15's in case we ever do a really small show and don't need the subs.

More QSC gear is all but out of the question, frankly, it's a little too pricey. What are y'all's thoughts on Yamaha DXR and EV ELX?